Method and apparatus for producing controllably oriented fibrous product

ABSTRACT

The method of making a non-woven fibrous pad comprising a threedimensional network of individual fibers interconnected by bonding means where they cross and contact each other and having a surface textured with a pattern of undulating elevations separated by a respective pattern of undulating depressions wherein each of the elevations comprises a structural dome in which the ratio of cap wall unit weight to average web unit weight is less than 1.0. The method includes the step of subjecting an unbonded web of mechanically engaged fibers to successive forming operations between partly meshing, multiple cogged work members relocating fibers from the regions forming the peaks of the elevations to the regions forming the sidewalls thereof. Apparatus for producing such a fibrous pad comprises a pair of fiber orienting arrangements, one of which includes means forming a traveling cog surface and the other of which includes a plurality of synchronized cog members meshing successively with the cog surface. One of the fiber orienting arrangements includes a plurality of closely laterally spaced cog elements having channels therebetween aligned generally with the direction of travel of the cog surface, and a conveyor belt arrangement is disposed partly in the channels and diverges from a meshed region of the fiber orienting arrangements for feeding a fibrous web into the orienting arrangements or stripping a processed web therefrom.

United States Patent 11 1 Kamp |4 1 Feb. 20, 1973 1541 METHOD ANDAPPARATUS FOR PRODUCING CONTROLLABLY ORIENTED FIBROUS PRODUCT [211 App].No.: 101,370

Related U.S. Application Data Primary Examiner-William A. PowellAttorney-Paul A. Rose, John F. Hohmann and J. Hart Evans [57] ABSTRACTThe method of making a non-woven fibrous pad comprising athree-dimensional network of individual fibers interconnected by bondingmeans where they cross and contact each other and having a surfacetextured with a pattern of undulating elevations separated [63]Continuation-impart of Scr. No. 777,698, Nov. 21, by a respectivePattern of undulating depressions 1968, Pat. No. 3,616,159. wherein eachof the elevations comprises a structural dome in which the ratio of capwall unit weight to [52] U.S. Cl. ..156/199, 156/459, 161/130 v g web ui weight i less than 1.0. The method [51] Int. Cl. ..B3lf l/00 includesthe step of subjecting an unbonded web of [58] Field of Search ..156/196, 199, 219-221, mechanically engaged fibers to successive forming156/228, 252, 253, 290, 323, 459, 513, 582, operations between partlymeshing, multiple cogged 585, 586, 590, 592, 595; 264/119; 198/162, workmembers relocating fibers from the regions226,170,172;161/109,113,DIG.3,130, forming the peaks of the elevationsto the regions 131; 19/161 P, 93, 94, 95, 100, 106, 172, forming thesidewalls thereof.

128; 226/170 172; 26/69 Apparatus for producing such a fibrous padcomprises [56] References Cited a pair of fiber orienting arrangements,one of which includes means forming a traveling cog surface and UNITEDSTATES PATENTS the other of which includes a plurality of synchronizedcog members meshing successively with the cog surface. One of the fiberorienting arrangements includes 2,464,301 3/1949 Francis Ix/582x aplurality of closely laterally spaced cog elements 2,764,193 9/1956Knowles.... .....l56/459 x having channels therebetween alignedgenerally with 2,856,323 10/1958 Gord n ,,15 220 X the direction oftravel of the cog surface, and a con- 3,025,585 3/1962 Griswold ....19/161 P X veyor belt arrangement is disposed partly in the chan- 3,031,5003/1963 Griswold at .-l6l/70X nels and diverges from a meshed region ofthe fiber $137,893 7/1964 Gelpke P X orienting arrangements for feedinga fibrous web into 3,369,955 2/1968 Rudloff ..156/595 X the orientingarrangements or stripping a processed FOREIGN PATENTS OR APPLICATIONSweb 962.162 7/ 1964 Great'BTFi'n'...iTQQlLIl'LTiI..1'9/1'06 13 cl i 1Drawing Figures 627 4 JR/ERGZ) fl/F/EA (45) MV\4\\'\I\\A PATENTED HmI915 3,717. 53 2 SHEET 10F 8 j/r/gle (45) PATENTEDFEBZOIQYK 3,717. 532

SHEET u 0F 8 5g INVENTOR I [d A. K m m PATENTEB FEB 2 0 i975 SHEET 5 OF8 INVENTOR wai 14.11 01 7% PATENTEUFEBZOIGIB SHEET 6 U? 8 3456789|0H|Blllllllll NUMBER OF FORMING 0PEK4770/V6 QRXK PATENTED FEB 2 01573 SHEET8 OF 8 METHOD AND APPARATUS FOR PRODUCING CONTROLLABLY ORIENTED FIBROUSPRODUCT RELATED APPLICATIONS This application is a continuation-in-partof my copending application, Ser. No. 777,698, filed Nov. 21, l968 nowUS. Pat. No. 3,616,159 titled Controllably Orientated Fibrous Productissued Oct. 26, 197 l.

BACKGROUND AND SUMMARY OF THE INVENTION This invention relates generallyto the art of nonwoven fibrous structures and more particularly tononwoven resilient padding.

In the past various procedures have been developed for making non-woven,lofted, fibrous batts; and it is known in the art to counteract thegeneral physical weakness of these products by incorporating adhesivebinders and the like for locking the individual fibers together into astronger, more integral material. Where cushioning applications arecontemplated, the air lay procedure produces a reasonably resilientproduct at moderate web speeds; and while a batt of greater resiliencycan be produced in a carded batt by the needle punching procedure, thelatter method is characterized by low web speeds and an undesirable lossin the loft of the fibers.

Accordingly, it is an important object of the present invention toprovide advantageous methods and apparatus for the production of a new,non-woven, fibrous pad which has improved resiliency and which can beproduced at high machine speeds.

Another object of the invention is to provide advantageous methods andapparatus for the production of a non-woven, fibrous pad which ischaracterized by an unusually high resiliency per pound of fiber.

Still another object of the invention is to provide advantageous methodsand apparatus for the production of a non-woven, fibrous pad which has agreater overall volume and a greater surface area than the web fromwhich it is produced.

And still another object of the invention is to provide advantageousmethods and apparatus for the production of a pad of the type describedwhich is amenable to the addition of high levels of binder.

It is also known in the prior art to texture a fibrous sheet product, asby embossing; but these procedures tend to compress the material makingit less resilient, and actually weaken the material with respect to itsability to store compressive loads by thinning the material in thosesections running generally parallel with the thickness dimension. It istherefore a further object of the present invention to provideadvantageous methods and apparatus for the production of a non-woven,fibrous pad in which the fibers are selectively distributed indome-shaped structures having a lesser concentration of fibers in thedome caps than in the remainder of the structure.

A yet further object of the invention is to provide advantageous methodsand apparatus for the production of such a pad in which the fibers inthe dome sidewalls are selectively oriented to resist compressive loadsapplied to the face of the pad.

These and other objects and features of the invention will become moreapparent from a consideration of the following descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawing:

FIG. 1 is a perspective view of a piece of non-woven, fibrous paddingconstructed and produced in compliance with the present invention;

FIG. 2 is an enlarged elevational view taken in crosssection along theline 2-2 of FIG. 1 and showing the undulating elevations and depressionsas well as the general orientation of the fibers in the pad of FIG. 1;

FIG. 3 is a schematic elevational view of apparatus arranged to producethe fibrous pad of the invention;

FIG. 4 is an enlarged front elevational view of the cogged,fiber-orienting rolls or cylinders used in the apparatus of FIG. 3;

FIG. 5 is an end elevational view in cross-section showing thepreforming or bulking rolls used in the apparatus of FIG. 3;

FIG. 6 is a fragmentary view somewhat similar to the showing of FIG. 5but illustrating the alternate arrangement of the cog teeth;

FIG. 7 is an elevational view of one type of fiberorienting apparatususeful for producing the fibrous pad of the invention;

FIG. 8 is a schematic view of a modified form of apparatus for producingthe fibrous pad of the invention;

FIG. 9 is an elevational view of a type of fiber-orienting apparatussimilar to that of FIG. 7 but incorporating additional features;

FIG. 10 is an enlarged front elevational view of cogged, fiber-orientingrolls or cylinders of the type used in the apparatus of FIG. 3, butincorporating additional features;

FIG. 1 1 is a schematic view of a modified form of the apparatus forproducing the fibrous pad of the invention;

FIG. 12 is a chart of one example showing the relation of the resiliencyof the pad to fiber orientation and the amount of working to which thepad is subjected in processing; and

FIGS. 13 and 14 are perspective views of the cogged cylinders used inthe apparatus of FIG. 3 and arranged with conveyor belt elements todeliver a carded web to the cylinders and to strip a processed webtherefrom.

FIGS. 15 and 16 are perspective views of the apparatus of FIG. 13further arranged with hold-down belt elements to hold down the webduring processing.

DETAILED DESCRIPTION OF THE INVENTION Referring now in detail to thedrawings, specifically to FIGS. 1 and 2, a non-woven fibrous padconstructed in compliance with the present invention is indicatedgenerally by the reference numeral 20. The pad 20 comprises athree-dimensional network of individual fibers 22 that form a surfacewhich is textured with a pattern of undulating elevations 24, elevations24 being separated by a respective pattern of undulating depressions 26.The individual fibers are bonded where they cross and contact eachother, as by droplets of a suitable adhesive 28. The elevations 24comprise domeshaped structures whereas the depressions 26 comprisecorresponding, inverted dome-shaped structures; and as compared with anordinary carded web, the pad 20 exhibits an enhanced total surface areaand increased resiliency. While the pad 20, like conventional nonwovenmaterials, has a degree of translucense, it ordinarily has no visibleholes penetrating through the product.

Each of the domes comprising the elevations 24 and the depressions 26includes a cap wall 30 and a surrounding sidewall 32; and in compliancewith the features of the present invention, the fibers making up thedomes are distributed in greater concentration in the sidewalls than inthe cap walls. More specifically, the fibers in the pad 20 are arrangedso that the ratio of cap wall unit weight to the average web unit weightis less than 1.0; and in further accord with the invention, this ratioof cap wall unit weight to the average web unit weight is controlled tobe greater than about 0.2, the precise figure for this lower limit beinggoverned by the physical properties which are acceptable in each givensituation and selected to be such that no appreciable perforation of thepad is developed. In addition, the individual fibers in the sidewalls 32are advantageously oriented generally parallel with the thicknessdimension of the pad 20. The described arrangement achieves a highdegree of resiliency per pound of fiber used and is more readilypenetrated by bonding liquids than the starting web. 4

A wide variety of fibers may be used in the pad 20; and at the presenttime, out staple fiber having a crimp or fibrils to encourage mechanicalinterlocking is preferred. However, expanded tow may also be employed.The fibers may be natural fibers such as hogs hair, cotton, sisal andhemp, or they may be synthetic fibers such as nylon, rayon acetate,polyester, acrylonitrile polymers, polypropylene, and polyvinylidenechloride-polyvinyl chloride copolymers. Inorganic fibers such as glassfibers may also be used, and any of these various fibers may be usedalone or in admixture with others.

Great latitude is also available in the selection of the binder; andwhile substantially any binder which is compatible with the fiber may beemployed, exemplary binders include acrylic, polyvinyl chloride andsynthetic elastomer latices. Binder may be added in quantities varyingfrom to 100 percent of the weight of fiber utilized, Furthermore,bonding of the fibers may also be achieved by momentarily heatingthermoplastic fibers to their softening point.

The individual elevations 24 and depressions 26 may take various shapessuch as ellipsoidal (as shown), round, elliptical, or nearly square forexample. In the embodiment illustrated in FIGS. 1 and 2, which is shownapproximately to scale, the vertical projection of an individualelevation or depression is a rectangle measuring approximately. one cm.by one-half cm. Elevations and depressions of other sizes may also beemployed. In addition, the one-hundred-and-eighty degree phaserelationship between adjacent rows of elevations and depressions neednot be adhered to, and other phase relationships may be used. It is alsopossible to fill the depressions on one side of the pad as with the sameor a dissimilar fiber or with a foamed resin.

According to the method aspects of the present invention, a resilientnon-woven product, such as the pad 20, is produced by reorienting thefibers of a lofted web in successive stages. Most fibers can be thusreoriented in a substantially dry state. For certain types of fibers,however, it may be desirable prior to the reorientation step to wet thefibers with a fiuid such as water or to bond the web lightly with abinder or by needling or the like. Such pretreatment is useful when theweb is otherwise difficult to process because of such factors as shortfiber length, heavy denier, high degree of crimp or high degree ofnatural spring back or liveliness. The massaging, rubbing or wipingaction of smooth, partially intermeshing cog teeth serves to relocategenerally the horizontally disposed fibers from the incipiently formingdome caps of the undulating elevations and depressions to the morevertically disposed sections of the dome sidewalls. Whether the fibersin the initial web are oriented to produce isotropic properties oranisotropic properties is immaterial to the practice of the presentinvention since a reorientation and redistribution of the fibers isachieved.

Referring to FIG. 3, a carded web 34 of cut staple fibers is advanced toa processing station 36 where the web is subjected to successive formingoperations between partly meshing, multiple cogged work members,specifically first stage forming rolls 38 and second stage forming rolls40. Only two forming stages are suggested in FIG. 3 for simplicity ofillustration; and it is to be recognized that the optimum number offorming operations will vary with such factors as the type and length ofthe fibers in the web 34, the thickness and density of the starting weband the depth of the cog teeth on the work members 38 and 40. Inreorienting the fibers in the starting web 34, it is advantageous thatthe depth of the cog teeth in the subsequent work members besubstantially the same as the depth of the cog teeth in the precedingwork members, although under certain circumstances it is desirable thatthe subsequent work members have a greater cog tooth depth or that thesubsequent work members be meshed to a greater degree than the precedingwork members. In any event, engagement of the various work members withthe web being processed is synchronized as by means of the mechanicalinterlock achieved through common drive gearing 42.

The processing which the web 34 receives at station 36 produces anorientation of the fibers of the type generally illustrated in FIGS. 1and 2, and this process step bulks the structure and generates a highpercentage of load bearing fibers without deliberately breaking them,such as occurs during needling for example. An unbonded web 44 formedwith patterns of undulating elevations and depressions exits from thestation 36; and frictional effects between the fibers, arising due tothe high individual fiber crimp or fibril-interlock, are relied uponinitially to maintain integrity of the structure. Subsequent bondingachieves permanency of the web. In order to accommodate high machinespeeds, it is advantageous to apply the bonding agent in stages in orderto avoid distortion of light web structures. Accordingly, a lightcoating, on the order of 0.1 0.2 ounces per square yard may be appliedto one or both surfaces of the web 44 by spray nozzles 46 or othersuitable means. The bonding agent applied by means of the nozzles 46 issuitably dissolved or dispersed in a solvent for ease of application andto promote penetration into the web 44. In order to develop structuralstrength and stability in the processed web, the bonding agent is driedor cured in a drier 48; and upon leaving the drier 48, the web can betreated with less care and concern.

Additional binder material is then supplied by a surface spray stationor saturator 50 and the web is heated to cure or dry the binder in adrier 52 where the web is advantageously festooned. The finished web 54emerges from the drier 52 from whence it can be directed for furtherprocessing or wound up in a roll 56 for shipment.

Turning to a consideration of FIGS. 4-6 for a more detailed descriptionof the cogged work members 38 and 40, each of these elements issimilarly fabricated to comprise a central drum or shaft 58 upon whichis mounted a plurality of cog rings 60. Each of the cog rings 60 carriesa suitable number of cog teeth 62; and to produce spacing of the cogteeth 62 axially of the shaft or drum 58, the cog rings 60 are providedwith lateral shoulders 64, best seen in FIG. 4. As will also be seen inFIG. 4, spacing of paired shafts 58, while taking into consideration thelength of the cog teeth 62, is selected to provide a relatively deep butonly partly meshed engagement of the cog teeth of the upper and lowerrolls whereby to accommodate the fibrous web therebetween withoutexcessive compression. Furthermore, the lateral faces of the cog teeth62 are tapered in order to' cooperate with the axial spacing afforded byshoulders 64 in accommodating the material of the fibrous web. The shapeof the individual cog teeth in transverse cross-section is selected tocorrespond with the vertical projection of the elevations andundulations to be formed in the fibrous web, and the preliminary workmembers 38 may be considered as bulking rolls in that the pattern ofundulations is well established even in a single pass, as is shown inFIG. 5. The subsequent work members may be correspondingly considered asfiber-orienting rolls which redistribute the individual fibers into thedesired configuration described hereinabove.

In order to distribute the undulating elevations and depressions acrossthe width of the fibrous web, the cog rings 60 of each work drum aremounted with a relative angular displacement as described hereinaboveand as shown in FIG. 6. However, precise intermeshing registration ismaintained between each cogged work member and its intermeshing element.As illustrated in the drawings, the cog teeth 62 are alternated with thecorresponding cog spaces across the face of the roll or drum. However,it is to be recognized that the cog teeth may be staggered by afractional pitch other than onehalf pitch in either direction.

The cog teeth are fabricated to be smooth surfaced and with roundedcorners and edges in order to prevent catching individual fibers fromthe processed web. In addition, the cog teeth and even the cog ringsthemselves are preferably fabricated from an elastomeric material suchas an unfoamed polyurethane material of about 90 durometer hardness onthe Shore A scale. So fabricated, intrusion of a hard foreign objectbetween the relatively deeply engaged cog teeth is prevented fromfacturing the teeth or overloading the bearings for the work cylinders.

Some polyurethanes of a moldable nature are also of advantage formanufacture of the cog teeth and cog rings since they possess a lowcoefficient of friction and exhibit good wear resistance. Cogs of hardermaterials, including metals such as steel, aluminum, etc. would alsogive good results.

As stated hereinabove, the optimum number of forming operations forproducing maximum physical properties in the fabricated pad varies withsuch factors as the type and cut length of the fibers, the thickness anddensity of the starting web and the depth of the individual cog teeth.Turning to FIG. 7, a processing machine, indicated generally at 66, isparticularly arranged to accommodate a selected number of plural formingoperations from two to seven. More specifically, a primary rotatablework member 68 is mounted on a horizontal shaft 70 and includes atubular hub 72 which rotatably receives the shaft 70, an outercylindrical drum 74, and radial spokes or arms 76 which attach cylinder74 to the hub 72. The outer surface of cylinder 74 is provided with apattern of cog teeth 78 similar to the cog teeth described withreference to FIGS. 4-6 hereinabove; and advantageously, the drum 74 isarranged to have a relatively large diameter in order that the height ofthe cog teeth will be small compared with the circumference of the drumfor ease in stripping the processed web. Arcuately spaced about theperiphery of cylinder 78 are seven, smaller diameter satellite rolls ordrums 80. Each of the satellite drums 80 is suitably rotatably mountedon a radially adjustably positionable bracket 82 which is secured to amachine frame, a portion of which is indicated at 82, by means ofadjustment screws 84. In addition, the satellite drums 80 areindividually provided with multiple cog toothed outer surfaces which aresuitably arranged to mesh with the cogged surface of the primarycylinder 74.

In order to synchronize the rotation of primary cylinder 74 and thesatellite drums 80, a sprocket wheel 86 is secured to the work member 68for roation therewith; and correspondingly, an individual sprocket wheel88 is secured to each of the satellite drums 80 for rotation therewith.A sprocket chain 90 is trained over the sprocket wheel 86 and over theindividual satellite drum sprocket wheels 88; and in order to insureproper operation of the drive train, a suitable number of idlersprockets 92 are radially adjustably mounted on the machine frame 83 bymeans of brackets 94 and adjustment screws 96. In the event that one ormore of the satellite drums 80 is repositioned either into or out ofmeshed engagement with the primary work member 68, one or more of theidler sprockets 92 will be appropriately repositioned to take up orprovide, as the case may be, slack in the sprocket chain 90. Rotarydriving force may be applied at the central shaft 70 or at one of a pairof outlying sprocket wheels 98. The use of the sprockets 88 and chain 90is preferred for heavy and hard to work fibrous webs. For much usage,however, particularly with light webs, the normal cog engagement servesas an adequate drive means for the satellite rollers.

In order to conduct a web 34 through the several work stationsestablished in the machine 66, an endless infeed and stripper beltarrangement is directed over a system of fixed rollers 102 andpositionally adjustable roller 104. The rollers 104 are rotatablymounted on brackets 106 which are, in turn, swingably mounted to themachine frame 83 by pivots 108, the brackets 106 being arcuately slottedto pass the shanks of adjustment screws 110. Thus, the rollers 104 maybe moved in respective arcuate paths and positioned to apply a selecteddegree of tension in the stripper belt arrangement 100. The infeed andstripper belt arrangement 100 is trained through the enmeshed, cogtoothed work members in a manner to be described more fully hereinafterwith respect to FIGS. 13 and 14; but continuing with reference to FIG.7, an endless helper belt 112 is driven by a suitably powered drive roll114 and guided by an idler roll 116 to aid in delivering the carded web34 to the cogged work members. The processed web 44 is passed from themachine 66 and guided by an idler roller 118 to further processingstatrons.

The stripper belt arrangement 100 described above illustrates aparticular stripping means which is preferred for use in the invention.Any suitable stripping means couldbe used, however, such as flow of airdirected between the processed web and the first fiber orienting means.Preferably the air stream is directed at a point on the first fiberorienting means just beyond the locus of the engagement of the web bythe second fiber orienting means. A so called air knife is useful toprovide and direct this air stream.

It is to be understood further that while the apparatus of the inventionhas been illustrated as including a stripping means, particularly thestripper belt arrangement 100, such stripping means is not essential forall situations. In the processing of particularly stable webs it ispossible to omit the use of normally preferred special stripping means.Particularly stable webs of this type may be achieved by prebonding ofthe web by any suitable means prior to its introduction into themachine. Such suitable means include the use of latent binders,needling, or the like.

In order to optimize uniformity of the fiber orientation in theelevations and depressions of the resilient pad of the invention, it maybe desirable to perform a first series of work operations principallywith respect to one side of the web and a second series of formingoperations principally with respect to the opposite side of the web.Apparatus generally arranged for achieving this result is suggested inFIG. 8 where two machines similar to the machine 66 described withreference to FIG. 7 are arranged in tandem, one of the machines beinginverted in order that the respective work members or satellite drumsmay engage that side of the web which is opposite to that engaged by thesatellite drums of the other machine. Since the tandemized processingmachines of FIG. 8, designated respectively by the reference numerals66a and 66b, are constructed similarly to the processing machine 66 ofFIG. 7, like numerals have been used to designate like parts with thesuffix letters a and b being employed to distinguish the respectivemachine elements found in the apparatus of FIG. 8.

It is to be recognized that, in operation, the processing machine 66, aswell as its counterparts in the tandem machine arrangement of FIG. 8, isfashioned to support an incoming web of fibers on the cogged surface ofprimary drum 74 while the cogged surfaces of one or more satellite drumsare rotated in synchronism with the primary drum in partly meshedengagement therewith so that the cog teeth of the satellite drum ordrums wipe into the web to form respective drum in partly meshedengagement therewith so that the cog teeth of the subsequent drum ordrums engage the previously formed depressions and elevations torelocate fibers from the respective crest and root regions thereof tothe sidewall regions. After the infed web is processed in this manner ina substantially dry state, the fibers are bonded together as previouslydescribed so as to produce a resilient fibrous pad of the character ofpad 20 described hereinabove.

In FIG. 9 there is shown a fiber orienting machine identical to that ofFIG. 7 except that it has a second endless belt arrangement 130 directedover a system which inciudes an adjustable clearance idler roller 132and return idler rollers 134. The operation of the holddown beltarrangement is described more fully hereinafter with respect to FIGS. 15and 16. With reference to FIG. 9 all of the remarks applied above toFIG. 7 apply here to FIG. 9 as well. The roller 132 in FIG. 9 isrotatably mounted on bracket 136 which is, in turn, swingably mounted tosupport 138 by pivot 140, the bracket 136 being arcuately slotted topass the shank of adjustment screws 142. This permits positioning of theclearance idler roller 132 to achieve the desired angle at which thebelt system 130 breaks away from the web 44 produced by the machine.

FIG. 11 illustrates a dual machine similar to that described in FIG. 7but incorporating a second endless belt arrangement 130a and 130b.Included are two machines of the type shown in FIG. 9 and arranged intandem to cooperate with one another. Parts similar to those in FIG. 9have been given the same numbers with the suffix letters a and b. Itmust be recognized, however, that in this dual arrangement the same beltwhich is the first belt arrangement 10Gb on cylinder 74b is also thesecond belt arrangement 130a on cylinder 74a.

' Similarly the first belt arrangement 100a on cylinder patterns ofdepressions and elevations. Subsequently,

one or more of the cooperatively cogged satellite drums are rotated incorrespondence with the primary 74a utilizes the same belt which is thesecond belt arrangement 13017 on cylinder 74b. The two primary cylindersof the dual machine must be fully synchronized not only in speed butalso in the relative positions of their respectivecogs. Thissynchronization can be achieved by any suitable means such as the spurgear train 146 shown in FIG. 11. The incoming web 34 moves through themachine in the direction shown and is removed as oriented unbonded web44 for spraying or other processing to fix to web. Operation of thecogged teeth is as described for FIGS. 7 and 8.

The effect of utilizing a multiplicity of forming operations inaccordance with the principles of the present invention is clear fromthe data graphically presented in FIG. 12. These data represent workconducted on eight denier rayon viscose and constitute a first workingexample of the invention. Actual values are set forth as plotted pointsand generalized relationships are suggested in the form of curves. Acarded web having an average fiber weight of 2.2 ounces per square yardwas employed as the starting material, and uniform amounts of binderwere added to the respective samples after processing. The binder itselfwas made up of equal parts of polyvinyl chloride latex andacrilonitrilebutadiene latex. In determining the amount of fibertranslocation, slugs having a diameter of about 0.6 cms. were punchedout of the cap area of the undulating elevations of each specimen. Theelevations themselves had a vertical projected area that measuredapproximately 1 cm. by 0.5 cm.; and ten slugs were extracted from eachsample and their weight averaged for the determination.

From an examination of the upper portion of the chart, it will beapparent that the unit work load is optimized for this particularstarting web and this particular machine setting at between seven andtwelve forming operationsfThe upper curve also shows a rapid rise ofproperties from the unprocessed web to a maximum at about ten formingoperations followed by a rapid decay to approximately sixteen formingoperations. Comparing the lower curve, it will be apparent that theforegoing change in physical properties was accom panied by a thinningout of the web in the center or cap area of the dome from 100 per centto 45 per cent of the average web weight. Beyond 16 forming operations,the weight ratio stabilized, as did the physical properties,representing the built in clearances of the processing machine. It wasobserved, in the course of the foregoing studies, that shaping of theweb into the pattern of undulating elevations and depressions wassubstantially complete, to within seven per cent of maximum height,after one or two forming operations.

Turning to a consideration of FIGS. 13 and 14, various elements of thework station 36, described with reference to FIGS. 3-6, are shownarranged with an infeed and stripper belt arrangement 120 of the generaltype suggested for use with the processing machines of FIGS. 7 and 8. Ithas been found that the formed web has some tendency to cling to one ofthe cogged members, and it is ordinarily desirable to peel the formedweb gently and progressively and without distortion from that member,stripper belts being one advantageous means for accomplishing thisobjective. Use of stripper belt arrangements is of particular advantagewith lightweight webs on the order of 1.0 ounces per square yard or lessin weight. The stripper belt arrangement 120 specifically comprises aplurality of laterally spaced-apart belts 122 which run between theindividual cog rings 60 at the root of the space between the cog teethof the lower work element or drum. As is shown in FIG. 4, the cog rings60 are fashioned with inwardly sloping surfaces at the shoulders 64 todefine grooves 124, the location of individual stripper belts 122 inthese grooves 124 being suggested in FIG. 4. The individual stripperbelts 122 may comprise such things as monofilament nylon, nylon rope,solid rubber strands of circular cross-section, and coiled wire orgarter spring belting. The latter material is of particular advantagebecause of its ease of splicing.

Under some circumstances, as for example when the cog teeth are at otherthan one-half pitch spacing axially of the work drums, it isadvantageous to include a series of cross belt elements 126, assuggested in FIG. 14, the set of cross belt elements runningtransversely of the first belt elements and connected thereto at pointsof contact to form a mesh.

In FIGS. and 16 is shown a second belt arrangement 150 of the typesuggested for use with the processing machines of FIGS. 9 and 11. It hasbeen found that with multiple satellite drums 80 cooperating with theprimary cylinder 68 of FIG. 9, the webs of some fibers have a tendency,in varying degrees, to be lifted from the primary cylinder surface by asatellite drum and then redeposited on the primary cylinder cog surfaceby the next successive satellite drum. Such action produces undesirablesurface irregularities and, in extreme cases, a non-uniform processedweb wherein some areas are thicker than others. The second beltarrangement 150 prevents'this undesired effect by holding the web downand maintaining it in contact with the cogged surface 78 of the primarycylinder 68 during all interaction of the primary cylinder 68 with thesatellite drurns 80.

In the corresponding work station 36 of FIGS. 15 and 16 the hold-downbelts 144 of the belt arrangement 150 hold down the web 34 as it is fedbetween the rolls 38 and on into rolls 40 and as the processed web 44emerges from the rolls 40 it is held down by the belts 144 so that itcannot lift off the belts 122 of the stripper belt arrangement 120. Theposition of the belts 122 and 144 relative to the rolls 40 can be seenin FIG. 10.

In order to describe the invention more fully, the following additionalspecific examples are given without, however, limiting the invention tothe precise details and conditions set forth.

A number of resilient pads were made in compliance with the principlesof the invention using two separate cut staple fiber base carded webs,specifically a rayon viscose of 15 denier and a staple length of 1 and9/16 inches and a rayon viscose of eight denier and one inch cut staplelength. A single binder was employed at different levels of addition,the binder in each case being equal parts of Geon 580 (polyvinylchloride latex) and I-Iycar 1552 (acrylonitrile-butadiene latex).

Processing of the carded webs was achieved on a work fixture in whichthe forming cog teeth were based on a linear pitch distance of 0.392inches and a transverse spacing of 0.31 inches. Alternate cog rings werestaggered one-half pitch, and the pitch diameter was chosen to be 4.50inches. Webs were processed in four forming operations, and productswere treated at linear web speeds of up to about 180 f.p.m. Thedifferent examples produced in this way and their resultant physicalproperties are set forth in Table 1 below:

TABLE 1 Example Number 2 3 4 5 6 7 8 9 Fiber denier 15 15 15 15 8 8 8 8Fiber batt weight ounces per sq. yd... 3.085 3.63 2.14 2.1 3.94 3.4 2.262.37 Binder add-on ounces per sq. yd 1.7 .575 1.57 .90 1. 87 .99 1.73.89 Percent solids in hinder (measure of penetration) 44 25 25 44 25 4444 25 Compression (lbs.) 33 34.5 25 14. 5 45.5 30. 5 22 22 Work absorbedin compr. inch-lbs"... 2. 85 3.26 2. 42 1.10 4.52 2.29 1.71 1.88Breaking strength,

lbs. (eve. 012 directions) 19 11 0.5 22 12 21.5 15.5 Percent elongationat I (ave. 012

direction) 63 45 79 64 59 1 Not obtained.

Having now described the invention in specific detail and exemplifiedthe manner in which it may be carried into practice, it will be readilyapparent to those skilled in the art that innumerable variations,applications, modifications and extensions of the basic principlesinvolved may be made without departing from the spirit and scope of theinvention. Thus, the fibrous resilient pads of the present invention maybe laminated with various fabrics, with paper or with other materials,to be employed in numerous ways that will be readily apparent to theskilled artisan, such as for example in lightweight resilient orinsulating structures and padded garments.

What is claimed is:

1. Apparatus for producing a non-woven fibrous pad comprising: firstfiber orienting means including means forming a continuous traveling cogsurface; and second fiber orienting means including a plurality ofindividual transversely extending synchronized cog-surfaced membersspaced in the direction of travel and meshing successively with saidtraveling cog surface.

2. Apparatus according to claim 1 wherein said traveling cog surface isarranged on the periphery of a cylindrical drum.

3. Apparatus for producing a non-woven fibrous pad comprising: firstfiber orienting means including means forming a continuous traveling cogsurface; second fiber orienting means including a plurality ofindividual transversely extending synchronized cog-surfaced membersspaced in the direction of travel and meshing successively with saidtraveling cog surface; and stripping means for stripping a processed webfrom said first fiber orienting means after the final engagement of saidweb by said second fiber orienting means.

4. Apparatus according to claim 3 wherein said traveling cog surface isarranged on the periphery of a cylindrical drum.

5. Apparatus according to claim 3 wherein said stripping means includesan air stream directed between said processed web and said first fiberorienting means.

6. Apparatus for producing a non-woven fibrous pad comprising: firstfiber orienting means including means forming a continuous traveling cogsurface; second fiber orienting means including a plurality ofindividual transversely extending synchronized cog-surfaced membersspaced in the direction of travel and meshing successively with saidtraveling cog surface, one of said first and second fiber orientingmeans including a plurality of closely laterally spaced cog elementshaving channel means therebetween running generally in the direction oftravel of said traveling cog surface; and conveyor belt means disposedpartly in said channel means and diverging from a meshed region of saidfirst and second fiber orienting means for feeding a fibrous web intosaid fiber orienting means or stripping a processed web therefrom.

7. Apparatus according to claim 6 wherein said traveling cog surface isarranged on the periphery of a cylindrical drum.

8. Apparatus according to claim 6 wherein said conveyor belt meansincludes laterally spaced belt elements running generally parallel withthe direction of travel of said traveling cog surface.

9. Apparatus according to claim 6 wherein said conveyor belt meansincludes first belt elements running generally parallel with thedirection of travel of said traveling cog surface directly beneath thefibrous web being processed through said apparatus and second beltelements running parallel to said first belt elements in the samedirection directly above and in contact with said fibrous web.

10. Apparatus according to claim 6 wherein said conveyor belt meansincludes first and second belt elements running generally parallel withthe direction of travel of said traveling cog surface and third beltelements running transversely of said first belt elements and connectedthereto forming a mesh.

11. Apparatus according to claim 6 wherein said conveyor belt meanscomprises a plurality of round extruded elastomer belts.

12. Apparatus according to claim 11 wherein said elastomer ispolyurethane.

13. The method of producing a non-woven fibrous pad possessed of asurface textured with a pattern of undulating elevations separated by arespective pattern of undulating depressions from an unbonded web ofmechanically engaged fibers, which method comprises: feeding said web toa processing station; subjecting said web to successive formingoperations between partly meshing, multiple cogged work membersrelocating fibers from the regions forming the peaks of said elevationsto the regions forming the sidewalls thereof; and bonding said formedweb to lock said fibers in their reoriented relationship.

14. The method according to claim 13 wherein said successive formingoperations are performed with the web in a substantially dry state.

15. The method according to claim 13 wherein first forming operationswork principally on one side of the web and second forming operationswork principally on the opposite side of the web.

16. The method of producing a non-woven fibrous pad possessed of asurface textured with a pattern of undulating elevations separated by arespective pattern of undulating depressions from an unbonded web ofmechanically engaged fibers, which method comprises: supporting said webon a cogged surface; rotating a first correspondingly cogged drum meansin partly meshed engagement with said surface, the cog teeth of saiddrum means wiping into said web to form said depressions and elevations;rotating a second correspondingly cogged drum means in partly meshedengagement with said surface and subsequent to said first drum means,the cog teeth of said second drum means engaging said depressions andelevations to relocate fibers from the respective crest and root regionsthereof to the sidewall regions; and bonding said formed web to locksaid fibers in their reoriented relationship.

17. The method according to claim 16 wherein said second drum meanscomprises a plurality of cogged drum elements.

18. The method of producing a non-woven fibrous pad possessed of asurface textured with a pattern of undulating elevations separated by arespective pattern of undulating depressions from an unbonded web ofmechanically engaged fibers, which method comprises: feeding said web toa processing station; subjecting said web to successive formingoperations between partly meshing, multiple cogged work membersrelocating fibers from the regions forming the peaks of said elevationsto the regions forming the sidewalls thereof; progressively peeling theformed web in substantially undistorted condition from a said workmember; and bonding said forrried web to lock said fibers in theirreoriented relationship.

1. Apparatus for producing a non-woven fibrous pad comprising: firstfiber orienting means including means forming a continuous traveling cogsurface; and second fiber orienting means including a plurality ofindividual transversely extending synchronized cog-surfaced membersspaced in the direction of travel and meshing successively with saidtraveling cog surface.
 2. ApparatUs according to claim 1 wherein saidtraveling cog surface is arranged on the periphery of a cylindricaldrum.
 3. Apparatus for producing a non-woven fibrous pad comprising:first fiber orienting means including means forming a continuoustraveling cog surface; second fiber orienting means including aplurality of individual transversely extending synchronized cog-surfacedmembers spaced in the direction of travel and meshing successively withsaid traveling cog surface; and stripping means for stripping aprocessed web from said first fiber orienting means after the finalengagement of said web by said second fiber orienting means. 4.Apparatus according to claim 3 wherein said traveling cog surface isarranged on the periphery of a cylindrical drum.
 5. Apparatus accordingto claim 3 wherein said stripping means includes an air stream directedbetween said processed web and said first fiber orienting means. 6.Apparatus for producing a non-woven fibrous pad comprising: first fiberorienting means including means forming a continuous traveling cogsurface; second fiber orienting means including a plurality ofindividual transversely extending synchronized cog-surfaced membersspaced in the direction of travel and meshing successively with saidtraveling cog surface, one of said first and second fiber orientingmeans including a plurality of closely laterally spaced cog elementshaving channel means therebetween running generally in the direction oftravel of said traveling cog surface; and conveyor belt means disposedpartly in said channel means and diverging from a meshed region of saidfirst and second fiber orienting means for feeding a fibrous web intosaid fiber orienting means or stripping a processed web therefrom. 7.Apparatus according to claim 6 wherein said traveling cog surface isarranged on the periphery of a cylindrical drum.
 8. Apparatus accordingto claim 6 wherein said conveyor belt means includes laterally spacedbelt elements running generally parallel with the direction of travel ofsaid traveling cog surface.
 9. Apparatus according to claim 6 whereinsaid conveyor belt means includes first belt elements running generallyparallel with the direction of travel of said traveling cog surfacedirectly beneath the fibrous web being processed through said apparatusand second belt elements running parallel to said first belt elements inthe same direction directly above and in contact with said fibrous web.10. Apparatus according to claim 6 wherein said conveyor belt meansincludes first and second belt elements running generally parallel withthe direction of travel of said traveling cog surface and third beltelements running transversely of said first belt elements and connectedthereto forming a mesh.
 11. Apparatus according to claim 6 wherein saidconveyor belt means comprises a plurality of round extruded elastomerbelts.
 12. Apparatus according to claim 11 wherein said elastomer ispolyurethane.
 13. The method of producing a non-woven fibrous padpossessed of a surface textured with a pattern of undulating elevationsseparated by a respective pattern of undulating depressions from anunbonded web of mechanically engaged fibers, which method comprises:feeding said web to a processing station; subjecting said web tosuccessive forming operations between partly meshing, multiple coggedwork members relocating fibers from the regions forming the peaks ofsaid elevations to the regions forming the sidewalls thereof; andbonding said formed web to lock said fibers in their reorientedrelationship.
 14. The method according to claim 13 wherein saidsuccessive forming operations are performed with the web in asubstantially dry state.
 15. The method according to claim 13 whereinfirst forming operations work principally on one side of the web andsecond forming operations work principally on the opposite side of theweb.
 16. The method of producing a non-woven fibrous pad possessed of asurface textured with a pattern of undUlating elevations separated by arespective pattern of undulating depressions from an unbonded web ofmechanically engaged fibers, which method comprises: supporting said webon a cogged surface; rotating a first correspondingly cogged drum meansin partly meshed engagement with said surface, the cog teeth of saiddrum means wiping into said web to form said depressions and elevations;rotating a second correspondingly cogged drum means in partly meshedengagement with said surface and subsequent to said first drum means,the cog teeth of said second drum means engaging said depressions andelevations to relocate fibers from the respective crest and root regionsthereof to the sidewall regions; and bonding said formed web to locksaid fibers in their reoriented relationship.
 17. The method accordingto claim 16 wherein said second drum means comprises a plurality ofcogged drum elements.